Automatic electrical wedge connector

ABSTRACT

An electrical wedge connector comprising a shell, and a wedge. The shell defines a wedge receiving passage therein. The wedge is shaped to wedge against the shell when inserted into the wedge receiving passage. The wedge has a conductor receiving channel therein for receiving and fixedly holding a conductor in the shell when the wedge is wedged into the shell. The shell has first portion with a first flexure stiffness generating a first clamping force on the wedge when the wedge is wedged in the first portion of the shell. The shell has a second portion with a second flexure stiffness generating a second clamping force on the wedge when the wedge is wedged in the second portion of the shell.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates to electrical wedge connectors and,more particularly, to an improved automatic electrical wedge connector.

[0003] 2. Brief Description of Earlier Developments

[0004] Power connectors, such as splice, reducer, or dead-end connectorsare used for connecting power distribution conductors by various userssuch as electrical contractors, electrical utilities, andmunicipalities. In order to ease installation, which may have to beaccomplished outdoors in very difficult access and weather conditions,possibly on “live” overhead wires, users have employed automaticoverhead connectors. In automatic overhead connectors, the wedge holdingthe power conductor in the connector is spring loaded to urge the wedgeautomatically into the connector. Conductor tension (due to theconductor weight) and friction between wedge and conductor does the restthereby wedging the wedge into the connector. In order to furthersimplify installation, overhead power connectors are sized generally tobe used with a number of conductors of varying sizes. For example, oneoverhead connector may be used for connecting conductors from 0.23 inchdiameter up to 0.57 inch diameter. This allows the user to select from,and hence have to carry a smaller number of different sizes ofconnectors at the job site. The structure of a given overhead powerconnector is capable of supporting the maximum connection loads (such asfor example prying loads from the wedge against the connector shell)when connecting the largest size conductor which may be used with theconnector. The connector structure is thus sized accordingly. U.S. Pat.No. 6,076,2336 discloses on example of a conventional cable connectorwhich has a body supporting opposing jaws for gripping a cable withwedge action, and a latch plate to retain the jaws in an open positionto relieve the cable. Another example of a conventional connector isdisclosed in U.S. Pat. No. 4,428,100 wherein the connector has a mainbody with a recess that has a gripping jaw slideably supported therein.The jaw is held in an open position by release pins. Still anotherexample of a conventional connector is disclosed in U.S. Pat. No.5,539,961 wherein a spring loaded wedge dead end with jaws spring loadedto a closed position that may be locked open by tabs on a floater. Thepresent invention overcomes the problems of conventional connectors aswill be described greater detail below.

SUMMARY OF THE INVENTION

[0005] In accordance with the first embodiment of the present invention,an electrical wedge connector is provided. The connector comprises ashell, and a wedge. The shell defines a wedge receiving passage therein.The wedge is shaped to wedge against the shell when inserted into thewedge receiving passage. The wedge has a conductor receiving channeltherein for receiving and fixedly holding a conductor in the shell, whenthe wedge is wedged into the shell. The shell has a first portion with afirst flexure stiffness generating a first clamping force on the wedgewhen the wedge is wedged in the first portion of the shell. The wedgehas a second portion with a second flexure stiffness generating a secondclamping force on the wedge when the wedge is wedged in the secondportion of the shell.

[0006] In accordance with a second embodiment of the present invention,an electrical wedge connector is provided. The connector comprises aframe, and a wedge. The frame has at least one shell section withopposing walls defining a wedge receiving passage in between. The wedgeis shaped to wedge against the opposing walls of the shell when thewedge is inserted into the wedge receiving passage. The wedge has aconductor receiving channel therein for receiving and fixedly holding aconductor in the shell when the wedge is wedged into the shell. Theopposing walls of the shell have stiffeners depending therefrom. Thestiffeners are distributed along at least one of the opposing walls withunequal spacing between adjacent stiffeners.

[0007] In accordance with another embodiment of the present invention,an electrical wedge connector is provided. The connector comprises ashell, and a wedge. The shell has a wedge receiving passage formedtherein. The wedge is adapted to wedge in the wedge receiving passagefor capturing a conductor in the shell. The shell has a first end with arounded outer guide face for guiding the wedge connector into astringing block pulley when the conductor captured in the shell ispulled over the stringing block pulley.

[0008] In accordance with still another embodiment of the presentinvention, an electrical connector is provided. The connector comprisesa frame, and a pair of opposing wedge members. The frame has a shellwith a wedge receiving channel. The pair of opposing wedge members arelocated in the wedge receiving channel for clamping a conductor in theshell. At least one wedge member of the pair of opposing wedge membershas a stand off projection which contacts and holds an opposing wedgemember at a standoff. The standoff projection has two stop surfaces forcontacting the opposing wedge member and holding the opposing wedgemember at two different standoffs from the at least one wedge member.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The foregoing aspects and other features of the present inventionare explained in the following description, taken in connection with theaccompanying drawings, wherein:

[0010]FIG. 1 is an exploded perspective view of an electrical wedgeconnector incorporating features of the present invention in accordancewith one embodiment, and two conductors;

[0011]FIG. 2 is a plan view of the frame of the wedge connector in FIG.1;

[0012] FIGS. 3A-3B respectively are bottom perspective views of theopposing wedge members of the wedge connector in FIG. 1;

[0013] FIGS. 4A-4C are partial plan views of the wedge connector in FIG.1 respectively showing the opposing wedge members in three positions inthe wedge connector;

[0014]FIG. 5 is a perspective view of a conventional stringing blockused with the wedge connector in FIG. 1;

[0015]FIG. 5A is a partial elevation view of the wedge connector in FIG.1 seated on the stringing block; and

[0016]FIG. 6 is a perspective view of a wedge connector in accordancewith another embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0017] Referring to FIG. 1, there is shown an exploded perspective viewof an electrical wedge connector 10 incorporating features of thepresent invention and two conductors A, B. Although the presentinvention will be described with reference to the single embodimentshown in the drawings, it should be understood that the presentinvention can be embodied in many alternate forms of embodiments. Inaddition, any suitable size, shape or type of elements or materialscould be used.

[0018] The connector 10 is depicted in FIG. 1 and described below asbeing a splice connector intended to connect ends of the two conductorsA, B. The present invention, however, applies equally to any othersuitable type of connector. The conductors A, B are shown in FIG. 1 asexemplary conductors. Conductors A, B are substantially similar. Theconductors may be power conductors, such as for example twisted wireconductors of any suitable size. In alternate embodiments, theconductors may be any other suitable type of conductors, and may havedifferent sizes.

[0019] The connector 10 generally comprises a frame 12, a first wedge14, a second wedge 16, and springs 18. In alternate embodiments lessfeatures or additional features could be provided. The first and secondwedges 14, 16 are located in the frame 12. The wedges 14, 16 can slidein the frame 12 between an open position and a closed or wedgedposition. The springs 18 are installed between the frame 12 and wedges14, 16 to pre-load the wedges to the closed position. The conductors A,B are placed in the corresponding wedges 14, 16 when the wedges are inthe open position. The conductors A, B are clamped in the connector 10when the wedges 14, 16 are moved automatically by the spring pre-load tothe closed position as will be described in greater detail below. Theconnector 10 has features which are substantially similar to connectorfeatures disclosed in U.S. patent application Ser. No. 09/794,611, filedFeb. 27, 2001, incorporated by reference herein in its entirety.

[0020] In greater detail now, and with reference to FIG. 2, the frame 12is preferably a one-piece metal member, such as a cast metal member.However, the frame could be comprised of more than one member, could becomprised of any suitable material(s), and/or could be made by anysuitable manufacturing process. In the embodiment shown in FIGS. 1-2,the frame 12 generally has a middle section 20 and two end sections 22,24 connected to each other by the middle section 20. The two endsections 22, 24 are substantially mirror images of each other. However,in alternate embodiments they could be different. Each section 22, 24comprises an open shell section 23, 25 having a general C shape.Accordingly, each shell section has opposite walls 26, 28 connected by aspan wall 40, which will be referred to hereinafter as the bottom wallfor convenience purposes only. As seen best in FIG. 2, the opposite sidewalls 26, 28 of each section 23, 25 are angled relative to each othertapering in from inner to outer ends of the section. Within the shell,the opposite side walls 26, 28 form wedge shaped receiving areas 30, 32.The receiving areas are sized to receive respective wedges 14, 16therein. Each shell section 23, 25 can have stiffeners to strengthen thesections as will be described further below. Each shell section 23, 25has a substantially open side (referred to hereinafter as the top sidefor convenience purposes only) which extends into the receiving areas30, 32. The tops of the side walls 26, 28 include inwardly extendingretaining lips 38. The outer end 34, 36 of each shell section has aconductor passage aperture 34A, 36A into the receiving areas 30, 32. Theshell section 23, 25 is sufficiently long to so that the mating wedge14, 16 may be placed in several positions within the corresponding shellsection, such as for example an open position, and several closedpositions. In this embodiment the middle section 20 of the connectorframe 12 is open on three sides. In this embodiment, the middle section20 connects the bottom wall 40 of the opposing shell sections 23, 25 toeach other. As seen in FIG. 2, the bottom wall 40 also includes springgrooves 46 and guide rails or projections 48. In alternate embodimentsthe spring grooves and guide rails may be extended into the middlesection of the connector frame. In other alternate embodiments the framecould have more or fewer features, arranged in any suitable manner onthe frame, and/or the features could have any suitable size or shape.

[0021] As noted before, each shell section 23, 25 has stiffeners 27A-27Eto strengthen and increase flexural stiffness of the shell section. Asthe two shell sections 23, 25 in this embodiment are substantiallymirror images, the description continues further below with specificreference to one of the sections 23 unless otherwise indicated. In thisembodiment, the stiffeners 27A-27E are ribs extending outwards from theopposite side walls 26, 28. The ribs wrap around to extend along thebottom side 40 of the shell section. In alternate embodiments, the shellstiffeners may have any other suitable shape providing the desiredstiffness to the shell section. Stiffeners 27A-27E are arrayed along theshell section 23, 25. The shell section 23 of the connector 10 in thisembodiment, is shown in FIG. 1 as having five stiffeners 27A-27E forexample purpose only. However, the shell section may be provided withany suitable number of stiffeners arrayed along the shell section. Thespaces 29A-29D between adjacent stiffeners 22A-27E on the shell sectionare not equal. As seen in FIG. 1, stiffeners 27C-27E towards the innerend 37 of the shell section are spaced closer together than stiffeners27A-27B located nearer the outer end 34 of the shell section. As seenbest in FIG. 2, in this embodiment, the consecutive spaces 29A-29Dbetween adjacent stiffeners 27A-27E are sequentially smaller from theouter end 34 to the inner end 37 of the shell section. Thus, forexample, the space 29A between the outermost stiffener 27A and theadjacent stiffener 27B is greater than the next consecutive space 29Bbetween stiffener 27B and consecutive adjacent stiffener 27C. Similarly,space 29C is smaller than space 29B, but smaller than the nextconsecutive space 29D. This progression may be continued for additionalstiffeners in those alternate embodiments where the shell section mayhave additional stiffeners. In other alternate embodiments, one or moreof the consecutive inter-stiffener spaces may be equal. As can berealized from FIGS. 1 and 2, the variance in the spaces 29A-29D betweenconsecutive adjacent stiffeners 27A-27E provides different portions ofthe shell section 23 with different flexural stiffenesses. In theembodiment shown in FIGS. 1-2 the closer spacing of the stiffeners27C-27E towards the inner shell end 37 (i.e. the wide part of the shell,section) causes the commensurate part of the opposite walls 26, 28 ofthe shell section to be flexurally stiffer than the part of the wallsnear the outer ends 34 where the stiffeners 27A, 27B are spaced furtherapart. Moreover the progressive decrease in space between consecutiveadjacent stiffeners from outer end 34 to inner end 37 results in theoutward flexural stiffeners of the opposite walls 26,28 increasingincrementally as the shell section widens. This allows the connector tobe used advantageously with a variety of different size conductors aswill be described in greater detail below.

[0022] Still referring to FIG. 1, the shell section 23, has a contouredportion 11 at the outer ends 34. Shell section 25 has contoured portion13 which is a mirror image of portion 11 at outer end 36. In alternateembodiments, only one end of the connector frame may have a contouredportion. The contoured portion 11 at the outer end of the shell sectionis shaped as will be described further below to cooperate with thepulley in a conventional stringing block as shown in FIG. 5 tofacilitate entry and passage of the connector 10 through the block aswill also be described further below.

[0023] With reference now to FIG. 5, the conventional stringing block Cgenerally comprises a support clevis C10 and pulley C12 rotatably heldin the clevis. The pulley C12 has a curved channel C14 in which aconductor (similar to conductors A, B) lies when it is being pulled overthe pulley. The stringing block, as seen in FIG. 5, has a cover or guardC14 over the pulley to retain the conductor on the pulley.

[0024] Referring now again to FIGS. 1-2, the contoured portion 11 has arounded outer guide face 3. The inner surface 54 of the contouredportion 11, which defines the conductor passage aperture into thereceiving area 30, is tapered or flared outwards as seen in FIG. 2. Theflared inner surface 4 has side portions 4A located on the opposite sidewalls and a bottom portion 4B across the bottom wall 40 of the shellsection 23. The portions 4A, 4B of the inner surface may be flared atany desirable angle in order to provide a smooth transition or supportsurface without edges against the conductor exiting the connector 10especially when the conductor in the conductor passage aperture may besomewhat bent. The rounded outer guide face has rounded portions orcheeks 3A on the opposite side walls 26, 28 and a generally radiusedlower portion 3B which transitions into bottom portion 4B of the innersurface. In the embodiment shown in FIGS. 1-2, the rounded portions 3Aon side walls 26, 68 provide an outward bulging transition from the edgeof the conductor passage aperture to the outermost stiffener 27A. Inalternate embodiments, the rounded outer guide surface may not extend tothe first stiffener of the shell section.

[0025] Referring now to FIGS. 1 and 3A-3B, the two wedges 14, 16 aresubstantially the same, but oriented in reverse orientations relative toeach other. However, in alternate embodiments more or less than twowedges could be provided, and the wedges could have different shapes.

[0026] In this embodiment each wedge has two wedge members 50 and 52.The wedge members 50, 52 are interlocked as will be described below tooperate in unison in the shell section. In alternate embodiments eachwedge could have more or less than two wedge members. Each wedge member50, 52 may be a one-piece cast metal member. However, in alternateembodiments the wedge members could comprise of multiple members, couldbe made of any suitable material(s), and/or could be formed by anysuitable manufacturing process.

[0027] The wedge members shown in FIGS. 1, and 3A-3B are exemplary wedgemembers, and in alternate embodiments the wedge members may have anyother suitable form or shape. The first wedge member 50 generallycomprises four sides 54, 56, 58, 60 located between a front end 62 and arear end 64. The inner side 54 has a curved conductor contact surface66. The inner side 54, proximate the bottom side 58, also comprises awedge member interlock projection 70. The top side 56 has an actuationor contact section 68 adapted to allow a user to grasp and move thefirst wedge when in the shell section. However, in an alternateembodiment the contact section might not be provided, or the wedgemember may have any other suitable type of section which allows the userto directly manipulate the wedge in the connector. The thickness of thefirst wedge member 50 between the two lateral sides 54 and 60 increasesfrom the front end 62 to the rear end 64 to form a general wedge shape.The bottom side 58 may include a spring engagement post or section 74,and a groove 76 sized to admit the guide rail 48 in the shell section(see FIG. 1). In this embodiment, the interlock projection 70 is a flattab which cantilevers outward from the inner side 54 of the wedge member50. In alternate embodiments, the interlock projection may have anysuitable shape. The tab projection has flat sides 71, 73 as seen in FIG.3A. The tab projection 70 terminates in a substantially flat snubber orstop surface 75. The outer corner along edge 73 of the tab projection iscut to form a step 77 into the tab. The step 77 provides the interlockprojection 70 with an inner stop surface 79.

[0028] The second wedge member 52 is preferably also a one-piece castmetal member. However, in alternate embodiments the second wedge membercould comprise multiple members, be made of any suitable materials(s)using any suitable manufacturing process. As seen best in FIG. 3B, thesecond wedge member 52 generally comprises four sides 78, 80, 82, 84located between a front end 86 and a rear end 88. The inner side 78 hasa curved conductor contact surface 90. The thickness of the second wedgemember 52 between the two sides 78 and 84 increases from the front end86 to the rear end 88 to form a general wedge shape. The bottom side 82generally comprises a spring engagement post or section 96, and a groove98 sized to receive corresponding guide rail 48 in the shell section.The bottom side 82 in this embodiment has an extension 94 which projectsfrom the inner side 78 of the wedge member 52. The extension 94 has afirst cutout 92 located and sized to form a sliding fit with theinterlocking projection 70 on wedge member 50 (see FIG. 3A). Cutout 92thus forms an interlock recess for projection 70 when the wedge members50, 52 are positioned in the shell section. Cutout 92 has a bottomcontact surface 92C as shown in FIG. 3B. The extension 94 has anadditional cutout 93, which in this embodiment adjoins the rear edge ofcutout 92. As seen in FIG. 3, cutout 93 forms a step 95 in the rearportion 94R of the extension 94. The bottom edge of the cutout 93 formsa stop surface 93C for engaging the inner stop surface 79 of theopposite wedge member 50.

[0029] FIGS. 4A-4C are partial plan views of connector 10 which show thewedge members 50, 52 placed in three positions in shell section 25. Theplacement of the wedge members in the opposite shell section 23 issubstantially a mirror image of the placement shown in FIGS. 4A-4C. InFIG. 4A, the wedge members 50, 52 are shown in a latched or openposition. This position may be an initial position of the wedge members50, 52 in the shell section 25. In FIGS. 4B-4C, the wedge members 50, 52are in two different engaged position. The general placement of thewedge members 50, 52 in the shell is similar in both open and engagedpositions. For example, the first wedge member 50 is located with outerside 60 against the inner surface of side wall 28 of the shell section.The bottom side 58 is located against the bottom 40 of the shell section25 with the spring engagement section 74 extending into respectivespring groove 46. One of the guide rails 48 extends into groove 76. Theretaining lip 38 of the side wall 28 extend over a portion of the topside 56 of the first wedge member. The second wedge member 52 is locatedagainst the inner surface of the opposite side 26 of the shell section25. The bottom side 82 is located against the bottom 40 with the springengagement section 96 extending into the respective spring groove 46similar to wedge member 50. Respective guide rail 48 extends into thegroove 98 of the wedge member 52. The retaining lips 38 of the side wall26 extends over a portion of the top side 80. Thus, both wedge members50, 52 are stably held in the shell section 25 and allowed to slide backand forth in the shell section along guide rails 48. The rails 48position the wedge members 50, 52 so that the outer sides 60, 84 of thewedge members 50, 52 contact the inner surfaces of the respective sidewalls 26, 28 at all positions in the shell section.

[0030] The springs 18, in the embodiment shown in FIG. 1, are coilsprings, but any suitable springs could be provided. In this embodimenta spring 18 is provided for each wedge member 50, 52. However, inalternate embodiments more or less springs could be provided, such asone spring for each pair of wedge members 50, 52 in the connector. Thesprings 18 in this embodiment are intended to be compression springs.Alternate embodiments may employ extension springs to pre-load the wedgemembers into the shell. The springs 18 are located in respective ones ofthe spring grooves 46. One end of each spring 18 is located against theinward closed end 47 of its respective groove 46. The opposite end ofeach spring is located against one of the spring engagement sections 74,96. The compression springs 18 exert forces on the wedge members 50, 52to bias the wedges 14, 16 along guide rails 48 towards the outer ends34, 36 of the frame 12. The wedge spring mechanism is a feature thatcauses the wedges to put an initial force on the conductor, placedbetween the wedge members during the insertion. The force is such thatit maintains enough friction between the wedges and the conductor suchthat, as the conductor is pulled during installation, it allows thewedges to “set” without the conductor slipping through the wedges. Theinterlocking features of the wedge member 50, 52 prevent one wedgemember from advancing at a different rate than the other. In thisembodiment the grooves for the springs are in the base of the body ofthe connector opposed to the sides of the body of the connector. Thisallows the wedges to have maximum surface contact with the sides of thebody of the connector. This maximizes the friction forces which may begenerated between wedges and shell section as well as improving theelectrical connection between the conductor in the connector and theframe of the connector.

[0031] As seen in FIG. 4A, in the open position, the wedge members 50,52 are in the widest section of the tapering shell section 25 proximatethe section inner end 37. The interlocking projection 70 of wedge member50 is located partially in cutout 92 in the opposite wedge member 52.The wedge members 50, 52 are offset longitudinally with respect to eachother sufficiently to align the step 77 in projection 70 with the matingstep 95 in the extension 94. The inner stop surface 79 of wedge member50 is seated against the outer stop surface 93C of wedge member 52. Thebias of springs 18 on the wedge members, along guide rails 48, into theshell section urges the opposing stop surfaces 79, 93C against eachother thereby locking the wedge members 50, 52 together. In order toplace the wedge members in the open position, once the wedge members 50,52 are installed in the frame 12, the user may merely press againstactuator section 68 to move the wedge towards the inner end 37 of theshell section. As the wedge members move back along rails 48, bothmembers moving in unison due to the interlock between, projection 70 isdrawn past stop surface 93C. At the point the spring bias wedge member52 automatically forces the stop surface 93C into step 74 and againststop surface 79 causing the wedge members to latch. The wedge membersare held stably in the open position until unlatched. To unlatch thewedge members, the user presses against actuator 68 toward outer end 36which causes wedge member 50 to move relative to wedge member 52 untilstop surfaces 79, 93C disengage. Once disengaged, the user may releasethe actuator 68 allowing the spring bias on the wedge members 50, 52 toautomatically move the wedges into the shell section to the positionsshown in FIGS. 4B-4C. The conductor A is placed between wedge members50, 52 in the connector 10 when the wedge members are in the openposition shown in FIG. 4A. As noted before, after release from the openposition, the wedge members automatically move to “grab” the conductorA. Pulling the conductor A during installation thus causes the wedges to“set” in the shell section 25.

[0032] As noted before, the wedges 14, 16 may be set in a number ofengaged or “set” positions in the shell sections 23, 25 depending on thethickness of the conductors A, B held in the wedges. FIGS. 4B-4C showtwo partial plan views of the connector 10 with the wedge 16 setrespectively in two “set” positions P₁ P₂ in the corresponding shellsection 25. In FIG. 4C the wedge 16 holds a conductor A, and in FIG. 4Bthe wedge 16 holds a conductor A′ which is thicker than but otherwisesimilar to conductor A in FIG. 4C. Accordingly, the wedge 16 is shown inFIG. 4C as being “set” in a position P1 closer to the outer end 34 ofthe shell section 25. In FIG. 2B, the wedge 16 is “set” in position P2which is set inward, closer to the inner end 37 of the shell section 25,relative to position P1 in FIG. 4C. In position P1, the wedge 16 pressesoutwards against sections 26A, 28A of the shell section side walls 26,28. In position P2, the wedge presses against sections 26B, 28B of theshell section side walls. As seen from FIGS. 4B-4C, in this embodimentthe stiffeners 27A, 27B are spaced further apart over sections 26A, 28Aof the side walls than the stiffeners 27C-27E along sections 26B, 28B.Hence, sections 26A, 28A have fewer stiffeners and correspondingly alower flexural stiffness and strength than section 26B, 28B.Nevertheless, the flexural stiffness and strength of sections 26A, 28A,and sections 26B, 28B respectively are suited to withstand the wedgingloads imparted by the wedge 16 when “set” in its corresponding positionsP1, P2. The wedging loads imparted by the wedge 16 against sections 26A,28A, 26B, 28B are dependent on the thickness of the conductors A, A′held by the wedge in the respective positions. By way of example,conductor A′ is thicker and hence heavier per unit length than conductorA. Accordingly, the tension loads on conductor A′, due to weight forexample, are also larger than corresponding tension loads on conductorA. Thus, when conductor A′ is held in the connector (the wedge islocated in position P2 shown in FIG. 4B), the higher tension loads causethe wedge 16 to impart higher wedging loads than when conductor A isheld in the connector. However, as noted before, the higher wedgingloads arising from conductor A′ are imparted against sections 26B, 28Bof the side walls which have the higher flexural stiffness and strengthsuited to support the higher wedging loads. Lower wedging loads arisingwith conductor A are imparted by the wedge 16 (in position P1 shown inFIG. 4C) against sections 26B, 28B of the side walls which have astiffness and strength suited to support the lower wedging loads.

[0033] Referring now again to FIGS. 1-2, and 5, after the conductors(such as for example conductors A, B in FIG. 1) are placed and wedgedinto the connector 10, the spliced conductors may be pulled throughstringing blocks (such as stringing block C in FIG. 5) duringinstallation. For example, stringing blocks similar to block C may beused for conductor installation onto power poles. Other guide blocks maybe used during conductor installation in large bore conduits orunderground pipes. As can be realized from FIG. 5, the pulley C12 in theblock C supports the conductor (similar to conductors A, B in FIG. 1)allowing the conductor to be pulled readily over the pulley when beingstrung onto the poles. As the conductor is pulled and passes through theblock C over pulley C12, the conductor rests in groove C14 of thepulley. The conductor has some flexibility even in larger conductorsizes. Hence, as the conductor passes over the pulley, the portion ofthe conductor resting on the pulley becomes curved somewhat along thecurvature of the pulley wheel. When the connector reaches the block, theouter end 34 of the connector contacts the perimeter of the pulley C12somewhere below the top most region C18 of the pulley (see FIG. 5A). Therounded outer guide face 3, seen best in FIGS. 1-2, contacts the sidewalls C15 of the groove C14 in the pulley. Continued pulling causes therounded lower portion 3B of the connector outer end to cam or ride uponto the pulley without catching or snagging on the pulley. As theconnector starts to rise on the pulley, outer rounded portions cooperatewith the side walls 15C (See FIG. 5) of the pulley groove 14 c to guidethe connector 10 into the groove C14. The flared or tapered innersurface 4B at the outer end 34 of the connector provides a smoothtransition for the conductor A between the portion resting on the pulleyand the portion in the connector 10. The tapered bottom portion of theouter end 34 of the connector between the inner 4B and outer 3B surfaces(See FIG. 5A) does not cause any sharp edges to be pressed into theconductor A as the connector end is pulled over the pulley C12. Anyinitial lateral misalignment between the pulley C12 and connector 10 isaccommodated by the inner side surfaces 4A (See FIG. 1). The lateralmisalignment causes the conductor A to bend laterally at the outer end34 of the connector. The flared inner side surfaces 4A allow theconductor to bend laterally without resting on any sharp edges at thebend. Flared inner surfaces 4A provide a smooth support surface for theconductor at the bend. The conductor may thus be pulled through thestringing block C without having the connector snag on the block.

[0034] Referring now to FIG. 6, there is shown a plan view of a dead endconnector 110 in accordance with another embodiment of the presentinvention, and conductor A installed in the connector. In thisembodiment, the dead end connector 110 has a frame 112 with a wedge endsection 124 and an elongated handling member 122 depending therefrom.The handling member allows the user to manipulate the dead end connectorand/or attach the dead end connector to structure or a handling device.In alternate embodiments, the handling member extending from the wedgesection may have any suitable shape. The handling member 122 is shown inFIG. 6, for example purposes, as being an elongated bar or post with atleast one attachment hole 123 at the end 132 of the member. The wedgesection 124 is substantially similar to the wedge section 22, 24 ofconnector 10 described before and shown in FIGS. 1-4. Similar featuresare similarly numbered. The wedge section 124 holds wedge 116 therein.Wedge 116 has two wedge members 150, 152 which are interlocking in amanner similar to that described for wedge members 50, 52 (See FIGS.3A-3B). The wedge members 150, 152 are automatically set by springs (notshown) similar to springs 18 held in the wedge section 124. The outerend 134 of the wedge section has rounded outer surfaces 103 and flaredinner surfaces 104. The side walls 126, 128 have stiffeners 127A-127Eseparated by sequentially smaller spaces 129A-129D between consecutiveadjacent stiffeners. Accordingly, the wedge section 124 has portion withdifferent strength and stiffness corresponding to different positions orthe wedge 16 in the wedge section.

[0035] As noted before, The structure of a given overhead powerconnector is capable of supporting the maximum connection loads (such asfor example prying loads from the wedge against the connector shell)when connecting the largest size conductor which may be used with theconnector. The connector structure is thus sized accordingly. However,in conventional overhead connectors, the connector structure especiallythe connector shell is substantially uniform or generic havingsubstantially the same strength and stiffness per unit length for thelength of the connector regardless of the magnitude of the connectionloads imparted on a particular portion of the connector. This results inexcess material being used in conventional overhead connectors with acorresponding increase in weight and also cost of the conventionalconnector. The effect of the excess weight of conventional overheadpower connectors is compounded in that, as indicated by their name,overhead power connectors are generally installed overhead, or to belifted overhead with the conductors. The excess weight of conventionalconnectors, hence, demands excess effort from the user to install.Connectors 10,110 overcome the problems of conventional connectors inthat the connector frame is tailored to provide suitable stiffness andstrength in those areas where it is desired. This results in a lighterand easier to use automatic connector which reduces installation costsfor power lines.

[0036] Furthermore, installation of conductors onto poles, generallyused to support overhead utility lines, or in underground conduits, mayemploy stringing blocks (such as shown in FIG. 5) used to support andguide the conductor as it is pulled to its installed position. Duringinstallation of the conductor, the connector, such as for example a deadend connector, may be used to grab onto the end of the conductor duringpulling. The connectors are then pulled through the stringing blockswith the conductor. Conventional overhead connectors generally haveblunt or flat ends which have a tendency to jam against the stringingblocks when the conductor is pulled. Significant effort may be used todislodge the conventional connector and pull it and the conductorthrough the stringing blocks. In sharp contrast to the conventionalconnectors, automatic connectors 10, 110 have rounded and contouredouter and inner surfaces which facilitate entry and passage of theconnector through the stringing block as described.

[0037] Further still, automatic overhead power connectors are desiredbecause of the automatic feature which automatically engages the wedgeinto the connector. Nevertheless, automatic overhead connectors areprovided with a latch or lock to hold the wedge in an open or unengagedposition against spring bias allowing the conductor to be placed intothe connector. Conventional overhead connectors employ a number oflatching devices which involve machining of catch facets on both wedgeand connector shell or manufacturing separate latch parts used to latchthe wedge in the shell. Machining latching facets or edges on the shellof conventional connectors are time consuming because of the complexgeometry of the shell (e.g. the shell is more difficult to position andhold in a fixture). Manufacturing separate latch parts dedicated tomerely holding the wedge in position in the shell is also costly andinefficient. In the connectors 10, 110 of the present invention thelatch features are included on the wedge members. This simplifiesmanufacturing of the latches in comparison to conventional connectors.Moreover, the latch feature of connectors 10, 110 is easily operated bythe user with one hand by merely pushing (on one tab) to engage and thenpushing to release the latch.

[0038] It should be understood that the foregoing description is onlyillustrative of the invention. Various alternatives and modificationscan be devised by those skilled in the art without departing from theinvention. Accordingly, the present invention is intended to embrace allsuch alternatives, modifications and variances which fall within thescope of the appended claims.

What is claimed is:
 1. An electrical wedge connector comprising: a shelldefining a wedge receiving passage therein; and a wedge shaped to wedgeagainst the shell when inserted into the wedge receiving passage, thewedge having a conductor receiving channel therein for receiving andfixedly holding a conductor in the shell when the wedge is wedged intothe shell; wherein the shell has a first portion with a first flexurestiffness generating a first clamping force on the wedge when the wedgeis wedged in the first portion of the shell, and has a second portionwith a second flexure stiffness generating a second clamping force onthe wedge when the wedge is wedged in the second portion of the shell.2. The connector according to claim 1, wherein the shell is a spliceconnector shell, a dead end connector shell or a reduction connectorshell.
 3. The connector according to claim 1, wherein the wedgecomprises a pair of opposing wedge members which define the conductorreceiving channel for holding the conductor between the opposing wedgemembers.
 4. The connector according to claim 3, wherein the opposingwedge members are spring loaded to bias the wedge member into the shell.5. The connector according to claim 1, wherein the wedge is located inthe first portion of the shell when the conductor has a firstcross-section held in the wedge, and wherein the wedge is located in thesecond portion of the shell when the conductor has a secondcross-section held in the wedge.
 6. The connector according to claim 5,wherein the second cross-section is larger than the first cross-section,and wherein the second flexural stiffness is higher than the firstflexural stiffness.
 7. The connector according to claim 1, wherein theshell has stiffeners depending outwards from opposite walls, the secondsection of the shell having more stiffeners arrayed along the oppositewalls than the first portion.
 8. The connector according to claim 7,wherein the stiffeners are spread along the opposite walls such that aspacing between consecutive adjacent stiffeners decreases from one endof the shell to another end of the shell.
 9. The connector according toclaim 8, wherein the shell has a tapered shape which narrows towards theone end of the shell.
 10. The connector according to claim 1, whereinthe shell has a one end with a rounded outer guide face for guiding theconnector into a stringing block pulley when the conductor held in theconnector by the wedge is pulled over the stringing block pulley. 11.The connector according to claim 1, wherein the wedge comprises a pairof opposing wedge members adapted for holding the conductor in-between,at least one of the opposing wedge members having a standoff tab forholding an opposing one of the wedge members at a standoff when thewedge is wedged into the shell.
 12. The connector according to claim 11,wherein the standoff tab has two support surfaces disposed to hold theopposing wedge member at two different standoff distances when the wedgeis wedged into the shell.
 13. An electrical wedge connector comprising:a frame having at least one shell section with opposing walls defining awedge receiving passage in-between; and a wedge shaped to wedge againstthe opposing walls of the shell when the wedge is inserted into thewedge receiving passage, the wedge having a conductor receiving channeltherein for receiving and fixedly holding a conductor in the shell whenthe wedge is wedged into the shell; wherein the opposing walls havestiffeners depending therefrom, the stiffeners being distributed alongat least one of the opposing walls with unequal spacing between adjacentstiffeners.
 14. The connector according to claim 13, wherein thestiffeners are disposed on the opposing walls to resist wedging forcesapplied by the wedge against the opposing walls when the wedge is wedgedin the wedge receiving passage.
 15. The connector according to claim 13,wherein the frame has another shell section at an opposite end of theframe from the at least one shell section.
 16. The connector accordingto claim 13, wherein the stiffeners on both opposing walls aredistributed along both opposing walls with unequal spacing betweenadjacent stiffeners.
 17. The connector according to claim 13, whereinspacing between consecutive adjacent stiffeners decreases sequentiallyfrom a first end to a second end of the shell section.
 18. The connectoraccording to claim 17, wherein the wedge is inserted into the shellsection from the second end to the first end.
 19. The connectoraccording to claim 13, wherein adjacent stiffeners at a first end of theshell section have a first intra stiffener spacing, and adjacentstiffeners at a second end of the shell have a second intra stiffenerspacing different than the first intra stiffener spacing.
 20. Anelectrical wedge connector comprising: a shell with a wedge receivingpassage formed therein; and a wedge adapted to wedge in the wedgereceiving passage for capturing a conductor in the shell; wherein theshell has a first end with a rounded outer guide face for guiding thewedge connector into a stringing block pulley when the conductorcaptured in the shell is pulled over the stringing block pulley.
 21. Theconnector according to claim 20, wherein the rounded outer guide facehas a curvature such that when the conductor is pulled over thestringing block pulley and the rounded outer guide face contacts agroove in the stringing block pulley, the rounded outer guide face andgroove cooperate to enable substantially unencumbered entry of the firstend of the shell into the stringing block pulley.
 22. An electricalconnector comprising: a frame having a shell with a wedge receivingchannel; and a pair of opposing wedge members located in the wedgereceiving channel for clamping a conductor in the shell, at least onewedge member of the pair of opposing wedge members having a standoffprojection which contacts and holds an opposing wedge member of the pairof opposing wedge members at a standoff; wherein the standoff projectionhas two stop surfaces for contacting the opposing wedge member andholding the opposing wedge member at two different standoffs from the atleast one wedge member.
 23. The connector according to claim 22, whereinthe opposing wedge member is held at a first standoff when a first ofthe two stop surfaces contacts the opposing wedge member, and is held ata second standoff when a second of the two stop surfaces contacts theopposing wedge member.
 24. The connector according to claim 22, whereinthe opposing wedge member has another standoff projection extendingopposite to the standoff projection of the at least one wedge member,the other standoff projection having other stop surfaces to contact theat least one wedge member.
 25. The connector according to claim 22,wherein the standoff projection is a tab extending from the at least onewedge member laterally towards the opposing wedge member.
 26. Theconnector according to claim 25, wherein the tab has a step formedtherein, lateral edges of the step forming the two stop surfaces of thestandoff projection.
 27. The connector according to claim 26, whereinthe opposing wedge member has another tab extending opposite to the tabof the at least one wedge member, and wherein the other tab has anotherstep reciprocal to the step in the tab.
 28. The connector according toclaim 22, wherein the opposing wedge members are spring loaded to biasthe wedge members into the shell, the standoff projection holding theopposing wedge member at two different standoffs against the spring loadbias.
 29. The connector according to claim 28, wherein a first stopsurface of the two stop surfaces engages a step in the opposing wedgemember to hold the opposing wedge member at an initial standoff, theinitial standoff between opposing wedge members causing the opposingwedge members to wedge against the shell in an initial position.
 30. Theconnector according to claim 29, wherein when the first stop surface isdisengaged from the step, the spring load moves the opposing wedgemembers into the shell until a second stop surface of the two stopsurfaces contacts the opposing wedge member.